2012-2013 Polaris Sportsman 400 H.O. / 500 Service Manual - All Models
2012-2013 Polaris Sportsman 400 H.O. / 500 Series technical guide: engine, fuel, transmission, and maintenance procedures. Includes part numbers for key components.
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Models Covered & Key Technical Specifications
2012-2013 Polaris Sportsman 400 H.O. / 500 Series Service Manual
This manual provides comprehensive repair and maintenance information for all 2012-2013 Polaris Sportsman 400 H.O. and 500 models, including Standard, Touring, Forest, and EFI variants.
2012-2013 Polaris Sportsman 400 H.O. & 500 Series (2012-2013) – Comprehensive Service & Repair Guide for All Standard, Touring, Forest & EFI Models Data-Compendium | Document Package
- System Specifications: 455cc engine displacement establishes the core performance parameters.
- Specific Engine Specs: For detailed component analysis, 87.9 x 75 mm defines the bore and stroke Range.
- Carburetor Specs: The main jet requires a 160 setting for optimal fuel delivery Configuration.
- Electrical Specs: The alternator output delivers 260 watts @ 3000 RPM Benchmarks.
- Ignition Specs: Ignition timing is set to 30° ± 2° BTDC @ 5000 RPM Sequences.
- Battery Specs: The maintenance-free battery provides 12 Amp Hr. Baseline.
Professional Workshop Service Manual & Technical Specifications
Polaris Sportsman 400 H.O. & 500 Series (2012-2013) Service Manual: Comprehensive Service & Repair Guide for All Standard, Touring, Forest & EFI Models Data-Compendium
Documentation-Type: Service Manual // Conceptual-Layout: Carburetor, Fuel System, Engine, Maintenance, Steering, Suspension, Body // Documentation-Type: Repair Guide
Polaris Sportsman 400 H.O. / 500 Series Service Manual Specifications
| Specification | Parameters | Framework |
|---|---|---|
| Engine Displacement | 455cc | Core Performance |
| Bore & Stroke | 87.9 x 75 mm | Component Range |
| Main Jet | 160 | Fuel Delivery Configuration |
| Alternator Output | 260 watts @ 3000 RPM | Electrical Benchmarks |
| Ignition Timing | 30° ± 2° BTDC @ 5000 RPM | Timing Sequences |
| Battery | 12 Amp Hr. | Baseline Power Source |
Featuring a modular arrangement of sections covering general information, engine disassembly and assembly, fuel system diagnostics, maintenance procedures, and body/steering/suspension component service. This manual details the critical systems necessary for keeping your Polaris Sportsman in optimal operating condition.
Engine Service
This section provides in-depth guidance on engine removal and installation, cylinder honing, crankshaft straightening, oil pressure tests, and detailed component inspections. It covers everything from camshaft timing to piston ring installation, ensuring a thorough understanding of the engine's mechanics.
Fuel System Service
Details the operation and service of both carbureted and EFI fuel systems. This includes carburetor adjustment, fuel pump testing, fuel filter replacement, and troubleshooting common fuel system issues like lean or rich mixtures and poor idle.
Maintenance Procedures
Outlines routine maintenance schedules and procedures, including pre-ride inspections, fluid level checks, filter replacements, and adjustments for various components like brakes and suspension. It emphasizes preventative maintenance for longevity and optimal performance.
Body, Steering & Suspension
Covers the removal and installation of body panels, bumpers, fenders, and storage components. It also details steering and suspension service, including A-arm and ball joint replacement, and strut cartridge service.
This manual documents torque specifications for critical fasteners to ensure proper assembly and the use of specialized tools where necessary for effective repairs.
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